How to Attach a Throttle Cable to a Dirt Bike
- 1). Park the dirt bike on its center stand or secure it on a repair stand. Loosen and remove the bolts at the seat fairing with a metric socket and ratchet. Save the bolts and any washers.
- 2). Lift the seat fairing enough to access the taillight wire connector at the taillight housing. Depress the tabs on the wire connector by hand and pull the connectors apart. Set the seat fairing aside.
- 3). Loosen and remove the bolts at throttle cable housing at the twist grip with a metric hex wrench. Remove the housing to expose the cable stop recess.
- 4). Fit the ball stop at the end of the throttle cable into the recess. Slide the stranded steel section of the cable into the slot next to the recess so the rigid cable tube hangs below. Reattach the housing and tighten the bolts.
- 5). Thread the rigid cable tube into the underside of the housing by hand until it's tight. Tighten the lock nut firmly against the housing with a metric wrench.
- 6). Route the other end of the throttle cable through the tubes or cable guides on the frame, starting at the front of the upper frame tube below the fuel tank. Insert the end of the cable through the tube or guide just above the linkage at the intake manifold and position the end alongside the carburetor or throttle-body linkage.
- 7). Loosen the fixing bolt at the linkage with a hex wrench. Insert the stranded steel end of the cable through the top of the adjuster coupler at the linkage and into the cable stop. Tighten the fixing bolt securely.
- 8). Twist the throttle grip as you observe the action of the linkage. Adjust the throttle cable with a metric wrench attached onto the adjuster coupler so the linkage activates simultaneously as you twist the throttle. Twist the throttle again and release it to ensure the linkage returns to the idle position. If necessary, readjust the cable so the linkage engages instantly and returns to idle.
- 9). Position the seat fairing above the bike. Reconnect the taillight wire connector. Reattach the fairing with the saved bolts and any washers that you removed. Tighten all bolts securely with the socket and ratchet.
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